Lab Session 12

 Objective: -
Design and draw a leaf jig for drilling two holes of 10 mm diameter on the given work
piece of stainless steel to produce a lot of 2000 of parts.

Figure No 1: Workpiece

1. Selection of Bush: -
We select the Headless type press fit bush as shown in following figure:

Figure No 2: Nomenclature of Bush

Drill Diameter = 10 mm
For 10 mm diameter,
The tolerance for the inner diameter of bush is d1F7 running fit.
d1 = 10 mm (+0.441, +0.020)
d2 = 18 mm (0, -0.013)
The tolerance for the outer diameter of bush is d2h6 pushes fit.
l2 = 16 mm
 Figure No 3: 3D View of Bush

Figure No 4: 2D View in 1st Angle of Projection

2. Selection of Locator and Supporting Block: -

Figure No 5: Locator
 Figure No 6: 3D View of Locator & Pin

Figure No 7: 2D View in 1st Angle of Projection

Figure No 8: 2D View in 1st Angle of Projection

Supporting Block: -
It is used to support the workpiece from bending during drilling operation. It is similar
to the hollow pipe as shown in following figure.

Figure No 9: Supporting Block

Figure No 10: 3D View of Supporting Block

Figure No 11: 2D View in 1st Angle of Projection

3. Selection of Clamp: -

Figure No 12: Clamp

d1 = 20 mm, e = 3.5 mm
d4 = 7.5 mm, f = 5 mm
d5 = 15 mm, h = 12 mm
d6 = 8 mm, r1 = 2 mm
d7 = 2 mm, r2 = 0.4 mm
The size of screw with thread is M10.

Figure No 13: 3D View of Clamp

 Figure No 14: 2D View in 1st Angle of Projection

4. Design of Jig Body: -

Width of the jig plate (W) = 50 mm
Length of the jig plate = 2Tp + Lw + clearance on both side
Where,
Tp – thickness of jig plate = 16 mm
Lw – length of workpiece = 95 mm
Clearance = 10 mm
Length of jig plate = (2 x 16) + 95 + (10 + 10) =147 (approx. 150 mm)

Height of Jig Plate = Tp + height of locator + workpiece + clearance for chip removal
Where,
Height of Locator = 10 mm
Workpiece = 42 mm
Therefore,
Height of jig plate = 16 + 10 + 42 + (10 + 10) = 88 mm (approx. 90 mm)

Width of Jig plate = Workpiece width + clearance on both side

Width of Jig plate = 30 + (10 + 10) = 50 mm
 Figure No 15: 3D View of Jig Body

Figure No 16: 2D View in 1st Angle of Projection

5. Design of Leaf: -
Length of Leaf = Length of Jig Plate
Length of leaf = 150 mm
Width of Leaf = Width of Jig plate
Width of Leaf = 50 mm
 Thickness of Leaf = Thickness of Jig Plate
Thickness of Leaf = 16 mm

Figure No 17: 3D View of Leaf

Figure No 18: 2D View in 1st Angle of Projection

6. Selection of Locking stud with nut: -

Leaf can be located by using a stud and an Allen screw with a C-washer.
Let the diameter of the stud is 10 mm, correspondingly other dimensions are taken.
 Figure No 19: 3D & 2D View of Allen type Screw

7. Bill of Materials (BOM): -

Sr. No. Part Name Material Quantity

1 Clamping Bolt Mild Steel 1
2 Bush Brass 2
3 Leaf Mild Steel 1
4 Jig Body Cast Iron 1
5 Supporting Block Mild Steel 1
6 Screw Mild Steel 4
7 Component Mild Steel 1
8 Locator Pin Mild Steel 1
9 Locator Mild Steel 1
8. Assembly of Leaf Jig and Components: -

Figure No 20: Assembly of Leaf Jig and its components

Figure No 21: 2D View in 1st Angle of Projection